Air blower validator, an hvac system and a method of manufacturing an hvac system

ABSTRACT

An air blower validator, a heating, ventilating and air conditioning (HVAC) system and a method of manufacturing thereof are disclosed. In one embodiment, the air blower validator includes: (1) a air pressure detector including a first pressure port configured to receive air from inside an air blower housing of an HVAC system and (2) an air collector configured to deliver the air to the first pressure port, the air collector including a pressure tap configured to couple to an opening in the air blower housing.

TECHNICAL FIELD

This application is directed, in general, to heating, ventilating and air conditioning (HVAC) systems, and more specifically, to air blower fans of HVAC systems.

BACKGROUND

In an HVAC system, an air blower is used to circulate air through an enclosure and the HVAC system. Typically, the air blower is used to pull air from the enclosure into the HVAC system through ducts and push the air back into the enclosure through additional ducts after conditioning the air (e.g., heating or cooling the air). To insure that the air blower is working properly, a system controller (e.g., a processor) is often used to monitor the operation of the air blower. One way of monitoring the air blower is by using an electrical switch to confirm if the motor is operating or not operating. Additionally, a pressure sensor may be used to determine if air is being moved by the air blower.

SUMMARY

In one aspect, an air blower validator for an HVAC system is disclosed. In one embodiment, the air blower validator includes: (1) a air pressure detector including a first pressure port configured to receive air from inside an air blower housing of an HVAC system and (2) an air collector configured to deliver the air to the first pressure port, the air collector including a pressure tap configured to couple to an opening in the air blower housing.

In another aspect, a method of manufacturing an HVAC system is disclosed. In one embodiment the method includes: (1) positioning a pressure tap of the air collector at a location of a housing of an air blower to capture air pressure in the air blower housing and (2) coupling the pressure tap to an opening at the location, wherein the pressure tap is coupled to a first pressure port of the air pressure detector.

In yet another aspect, an HVAC system is disclosed. In one embodiment, the HVAC system includes: (1) an air blower having an air blower housing and configured to circulate air through the HVAC system and (2) an air blower validator coupled to HVAC system, having: (2A) an air pressure detector including a first pressure port configured to receive the air from inside the air blower housing and (2B) an air collector configured deliver the air to the first pressure port, the air collector including a pressure tap configured to couple to an opening in the air blower housing.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:

FIG. 1A illustrates a block diagram of an embodiment of an HVAC system constructed according to the principles of the disclosure;

FIG. 1B illustrates a diagram of an air blower with an embodiment of an air blower validator constructed according to the principles of the present disclosure;

FIG. 2 illustrates a block diagram of one embodiment of an air blower validator constructed according to the principles of the disclosure; and

FIG. 3 illustrates a flow diagram of an embodiment of a method of manufacturing a HVAC system carried out according to the principles of the disclosure.

DETAILED DESCRIPTION

Employing pressure sensors to monitor the operation of an air blower can be expensive due to the sensitivity needed to measure the changes of air pressure. This can be especially true when variable speed motors are employed due to the small changes in air pressure between the various speeds. Typically, a more sensitive (and often more expensive) pressure sensor may be needed to detect air pressure changes at these low flow conditions. Thus, improvements in determining if an air blower is operating properly, i.e., moving air, can be advantageous.

This disclosure provides a proving device for an air blower that is connected to the housing of an air blower. The proving device, an air blower validator, includes an air collector coupled to a supply port or supply ports of an air pressure detector and configured to deliver air from within the housing of the air blower to the supply port or ports to allow detection of static pressure, total pressure or velocity pressure from the air blower. The air collector may include multiple sections. For example, the air collector may include a pressure tap and a supply conduit that couples the pressure tap to the supply port of the air pressure detector. The pressure tap may be coupled to an opening of the air blower housing and may extend through the air blower housing opening with an opening that faces air flow generated by the air blower. The supply conduit delivers air captured by the pressure tap to the supply port. The supply conduit may be external to the air blower housing. In some embodiments, the air collector may include a single section, the pressure tap. In these embodiments, the pressure tap may have one end that is coupled to the supply port and an angled-end that extends into the air blower housing and configured to capture total pressure, including velocity pressure, from the air blower housing. The air collector may include multiple pressure taps and supply conduits.

The pressure tap of the air collector may be positioned to capture a maximum total pressure or at least substantially the maximum total air pressure reading in the air blower housing. The mounting location for capturing maximum total air pressure may be determined by experimentation or theoretical calculation. (See, for example, “FANS,” by Theodore Baumeister, Jr., Mcgraw Hill Book Company Inc., 1935, pages 100-110). The location may vary for different air blower models. In some embodiments, utilizing radially or axially expanding blower designs, the location may be between 180-230 degrees from the cut-off section of the air blower.

By locating the pressure tap as disclosed in one of the embodiments herein, the air pressure detector may capture the added benefit of velocity pressure (e.g., 0.3″ water column (wc) or higher) that makes a total pressure reading reasonably above the operating settings of the air pressure detector. Thus, the air blower validator can be used repeatedly and reliably to monitor the operation of an air blower. This is especially useful for variable speed blowers operating at low flow conditions when changes in the total air pressure are difficult to detect.

FIG. 1A is a schematic diagram of an embodiment of an

HVAC system 100 constructed according to the principles of the present invention. The HVAC system 100 includes a return duct 110, a return plenum 115, an air blower 120, a supply plenum 130, a supply duct 140, a controller 150 and an air blower validator 160. One skilled in the art will understand that HVAC system 100 may include additional components and devices that are not presently illustrated or discussed but are typically included in an HVAC system, such as, cooling coils and heating elements. A thermostat (not shown) is also typically employed with a HVAC system 100 and used as a user interface.

The air blower 120 is configured to circulate air through an enclosure (not shown) by suctioning air from the enclosure through the return duct 110 and the return plenum 115, as indicated by arrow 112, and discharging air to the enclosure, as indicated by arrow 132 through the supply plenum 130 and the supply duct 140. The supply plenum 130 is in fluid communication with the supply duct 140 to supply discharged air to the enclosure. The air blower 120 may be a conventional blower used in HVAC systems to circulate air through an enclosure. In some embodiments, the air blower 120 may include a variable speed motor and operate at various speeds. The air blower 120 has a housing 122 that includes, for example, a blower motor and wheel (not illustrated).

Operation of the air blower 120 may be controlled by the controller 150 based on inputs from, for example a thermostat. The controller 150 may be a processor, such as a microprocessor, configured to direct the operation of the HVAC system 100. As illustrated in FIG. 1, the controller 150 may be coupled to the air blower validator 160 through a wired-connection. A cable may be used to couple the controller 150 to the air blower validator 160 through contacts (not shown) thereon. The cable and contacts may be conventional components typically used in a HVAC system. In some embodiments, a wireless connection may also be employed to couple the air blower validator 160 to the controller 150.

The air blower validator 160 is configured to prove the operation of the air blower 120. In other words, the air blower validator 160 is configured to verify that the air blower 120 is moving air. The air blower validator 160 includes an air pressure detector 162 and an air collector 164. The air pressure detector 162 is configured to indicate if the air blower 120 is operating properly based on air pressure (static, velocity or total air pressure which is velocity pressure+static pressure) associated with the air blower 120. The air pressure detector 162 includes a first pressure port configured to receive air from inside the air blower housing 122. In one embodiment, the air pressure detector 162 is a pressure switch and includes a second pressure port that receives air external from the air blower housing 122. In such an embodiment, the air pressure detector 162 compares the pressures associated with the air received from the two different locations and operates a switch based thereon. In another embodiment, the air pressure detector 162 may be a pressure transducer that converts the total pressure of the air received from the air blower housing 122 into an electrical signal. The electrical signal may then be delivered to the controller 150 to verify operation of the air blower 120. The pressure switch and the pressure transducer may be conventional devices. The air pressure detector 162 is connected to the air blower housing 122 and coupled to the pressure tap 166 of the air collector 164. The pressure tap 166 is coupled to the first pressure port and is positioned for the suspended opening to face the air flow direction of the air blower 120.

The air collector 164 is configured to extend into the air blower housing 122 and deliver air thereof to the first pressure port. The air collector 164 includes a pressure tap 166 configured to suspend in the air blower housing with an opening that faces air flow generated by the air blower. The pressure tap 166 may be an angled device as illustrated having an opening that faces the air flow generated by the air blower. The pressure tap 166, therefore, includes an end coupled to a pressure port of the air pressure detector and an uncoupled end that is suspended in the air blower housing 122 and faces the air flow direction during normal operation. As illustrated in FIG. 1B, an air collector may include a supply conduit that couples a pressure tap to the supply port of an air pressure detector.

FIG. 1B illustrates a diagram of an embodiment of an air blower validator 170 constructed according to the principles of the present disclosure. The air blower validator 170 is connected to an air blower housing 180. The air blower validator 170 includes an air pressure detector 172 and an air collector 174. The air pressure detector 172 may be an air pressure switch or an air pressure transducer as described above with respect to the air pressure detector 162 of FIG. 1A. Coupled to a pressure port of the air pressure detector 172 is the air collector 174. The air collector 174 includes a supply conduit 176 and a pressure tap 178. The pressure tap 178 is directly coupled to the air blower housing 180 and positioned to capture air pressure therein. The pressure tap 178 may be mounted directly to an opening of the air blower housing 180. The pressure tap 178, therefore, may be used to obtain static pressure from inside the air blower housing 180. In one embodiment, the pressure tap 178 may extend perpendicularly or at least substantially perpendicularly into the air blower housing 180 with respect thereto and be used to obtain total pressure from within the air blower housing 180. In one embodiment, the pressure tap 178 may extend between about 0.5 inches to about 0.75 inches into the air blower housing.

The pressure tap 178 may include a portion that is external to the air blower housing 180 and a portion that extends into the air blower housing 180. As illustrated, the supply conduit 176 may be external to the air blower housing 180. The length of the supply conduit 176 may vary allowing the air pressure detector 172 to be mounted in different locations. In some embodiments, the supply conduit 176 may be rubber tubing that is typically used to provide air from different locations to pressure sensors in HVAC systems.

In some embodiments, such as illustrated in FIG. 2, an air collector may include a pressure tap having a first end configured to couple to a first pressure port of an air blower detector and a second end that is uncoupled and configured to extend into the air blower housing 122 to capture the air. The second end may include an opening that is positioned to face an air flow direction generated by the air blower during normal operation.

FIG. 2 illustrates a diagram of an embodiment of an air blower validator 200 constructed according to the principles of the disclosure. The air blower validator 200 includes an air pressure detector 210 and an air collector 220. The air pressure detector 210 includes a first pressure port 212, a second pressure port 214 (represented by embodiments 214 a and 214 b), electrical contact(s) 216 and a base 218 that is used to mount the air pressure detector 210 to, for example, part of an air blower. Screws, such as sheet metal screws, or other mechanical fasteners may be used to couple the air pressure detector 210 to part of an HVAC system such as the air blower housing. Alternatively, an adhesive or another means for coupling may be used to connect the air pressure detector 210.

The first pressure port 212 extends from the air pressure detector 210 wherein the second pressure port 214 a is recessed. Alternatively, the second pressure port may also extend from the air pressure detector 210 as represented by 214 b. The air collector 220 includes a pressure tap 225 that is sized to fit over the extended first pressure port 212 and may be coupled to the first pressure port 212 via friction. In other embodiments, the pressure tap 225 may be coupled to the pressure port 212 via another means, such as an adhesive.

The pressure tap 225 may be constructed from rubber tubing that is typically used to provide air from different locations to pressure sensors in HVAC systems. In other embodiments, the pressure tap 225 may be constructed of another material, such as, plastic. One skilled in the art will understand that the pressure tap 225 may be constructed of various materials that allow the pressure tap 225 to be suspended in an air blower housing with an uncoupled end.

As illustrated, the pressure tap 225 has an angled-opening that is positioned to face the air flow generated by an air blower. The angled-opening is shaped to capture the total pressure in an air blower housing wherein the total pressure equals the static pressure and the velocity pressure. In one embodiment as illustrated, the angle of the angled-opening may be about 30 to 60 degrees with respect to longest side of the pressure tap 225.

The air collector 220 may also be coupled between the second pressure port 214 b and an opening of the air blower housing 218. The air collector 220 may be coupled to a nipple 219 of the air blower housing 218. Through this embodiment, the air blower validator 200 can obtain the velocity pressure via the difference of static pressure and total pressure provided to second pressure port 214 b and first pressure port 212, respectively.

FIG. 3 illustrates a flow diagram of an embodiment of a method of manufacturing an HVAC system carried out according to the principles of the disclosure. The HVAC system may be a commercial system that includes, for example, a rooftop unit. Alternatively, the HVAC system may be a residential system. Some of the steps of the method 300 may occur during manufacturing of the HVAC system. Additionally, some of the steps of the method 300 may occur during installation of the HVAC system. The method 300 begins in a step 305.

In a step 310, a pressure tap of an air collector is positioned at a location of a housing of an air blower of the HVAC system to capture air pressure in the air blower housing. The pressure tap may be used to collect total pressure or static pressure from inside the air blower housing. The air collector is part of an air blower validator that also includes an air pressure detector. In one embodiment, the air pressure detector may be, for example, a pressure switch. In another embodiment, the air pressure detector may be a pressure transducer. The location is determined to capture the maximum or at least substantially the maximum velocity pressure from the air blower. In one embodiment, the location may be within 180 to 230 degrees from the cut-off section of the air blower.

In a step 320, the pressure tap is connected to a pressure port of the air pressure detector. In one embodiment, the pressure tap may be connected via a supply conduit. In another embodiment, the pressure tap may be coupled directly to the pressure port. In one embodiment, an air collector including the pressure tap may be formed as an extension of the pressure port during manufacturing of the air pressure detector. In another embodiment, the air collector may be coupled to the pressure port after manufacturing of the air pressure detector. The air pressure detector may include multiple pressure ports and more than one of the pressure ports may be coupled to the air collector to receive air from inside the air blower housing.

At least a portion of the pressure tap is inserted inside the air blower housing in a step 330. A portion of the pressure tap may be inserted through an opening that was pre-cut before installation. In some embodiments, the opening may be cut during installation. A portion of the pressure tap may be inserted about 0.5 inches to about 0.75 inches into the air blower housing. The portion of the pressure tap inserted into the air blower housing suspends from the air blower housing and remains uncoupled.

In a step 340, the portion of the pressure tap inserted in the air blower housing is positioned to face an air flow direction generated by the air blower. The inserted portion of the pressure tap may have an angled-opening that is positioned to face the air flow. In some embodiments, the pressure tap itself may be angled with an opening that can be positioned to face the air flow direction. For example, the pressure tap may be angled at or about 90 degrees wherein a first end is connected to the pressure port and a second end is positioned to face the air flow direction and capture air. The pressure tap is positioned to capture both velocity pressure and static pressure for the air collector.

The air pressure detector is then connected to the HVAC system in a step 350. In one embodiment, the air pressure detector is connected to the air blower housing. The air pressure detector may be connected via a mechanical connection such as by using screws. The method 300 then ends in a step 360.

Those skilled in the art to which this application relates will appreciate that other and further additions, deletions, substitutions and modifications may be made to the described embodiments. 

1. An air blower validator, comprising: an air pressure detector including a first pressure port configured to receive air from inside an air blower housing of an HVAC system; and an air collector configured to deliver said air to said first pressure port, said air collector including a pressure tap configured to couple to an opening in said air blower housing.
 2. The air blower validator as recited in claim 1 wherein said pressure tap is configured to capture static pressure from inside said air blower housing.
 3. The air blower validator as recited in claim 1 wherein at least a portion of said pressure tap is configured to extend through said opening into said air blower housing and have an angled-opening configured to capture total pressure of said air blower.
 4. The air blower validator as recited in claim 1 wherein said pressure tap is configured to extend substantially perpendicularly into said air blower housing.
 5. The air blower validator as recited in claim 2 wherein said air pressure detector includes a second pressure port configured to receive air from inside said air blower housing, said air collector further configured to couple to said second pressure port and capture total pressure from inside said air blower housing.
 6. The air blower validator as recited in claim 5 wherein said air pressure detector is configured to provide velocity pressure of said air blower.
 7. The air blower validator as recited in claim 1 wherein said pressure tap is coupled to said first pressure port via a supply conduit.
 8. A method of manufacturing an HVAC system including an air blower validator having an air pressure detector and an air collector, comprising: positioning a pressure tap of said air collector at a location of a housing of an air blower to capture air pressure in said air blower housing; and coupling said pressure tap to an opening at said location, wherein said pressure tap is coupled to a first pressure port of said air pressure detector.
 9. The method as recited in claim 8 further comprising inserting at least a portion of said pressure tap inside said air blower housing through said opening.
 10. The method as recited in claim 9 further comprising positioning said portion of said pressure tap to suspend in said air blower housing wherein an opening thereof faces an air flow direction generated by said air blower.
 11. The method as recited in claim 10 wherein said pressure tap opening is an angled-opening.
 12. The method as recited in claim 10 wherein said location is based on capturing a maximum amount of total pressure from said air blower.
 13. The method as recited in claim 8 further comprising coupling a second pressure port of said air pressure detector to said air collector to capture total pressure from inside said air blower housing.
 14. The method as recited in claim 8 wherein said first pressure tap is coupled to said pressure port via a supply conduit.
 15. The method as recited in claim 8 wherein said location is within a range between 180 degrees to 230 degrees from a cut-off section of said air blower.
 16. An HVAC system, comprising: an air blower having an air blower housing and configured to circulate air through the HVAC system; and an air blower validator coupled to the HVAC system, including: an air pressure detector including a first pressure port configured to receive said air from inside said air blower housing; and an air collector configured to deliver said air to said first pressure port, said air collector including a pressure tap configured to couple to an opening in said air blower housing.
 17. The HVAC system as recited in claim 16 wherein said pressure tap is configured to capture static pressure from inside said air blower housing.
 18. The HVAC system as recited in claim 16 wherein at least a portion of said pressure tap is configured to extend through said opening into said air blower housing and have an angled-opening configured to capture total pressure of said air blower.
 19. The HVAC system as recited in claim 17 wherein said air pressure detector includes a second pressure port configured to receive air from inside said air blower housing, said air collector further configured to couple to said second pressure port and capture total pressure from inside said air blower housing.
 20. The HVAC system as recited in claim 19 wherein said air pressure detector is configured to provide velocity pressure of said air blower.
 21. The HVAC system as recited in claim 16 wherein said pressure tap is coupled to said first pressure port via a supply conduit. 